This document describes an experimental study of high density concrete conducted by civil engineering students. The study aimed to develop a mix design for M60 grade concrete and examine the properties of high density concrete incorporating hematite aggregate. Various materials were tested, including cement, aggregates, and hematite. Concrete mixes incorporating 10%, 25%, 50%, and 75% hematite aggregate were cast and their compressive strength, split tensile strength, and other properties were evaluated and compared to normal weight concrete. The results showed that high density concrete achieved higher strength values compared to normal concrete.

1. ANNAMACHARYA INSTITUTE OF
TECHNOLOGY AND SCIENCES
CIVIL ENGINEERING
PROJECT WORK
EXPERIMENTAL STUDY OF
HIGH DENSITY CONCRETE
PROJECT ASSOSIATES
K. Chandana – 20T85A0104
V. Anuradha – 20T85A0102
N. Rakesh - 20T85A0121
CH. Saikumar – 20T85A0124
UNDER GUIDANCE OF
Mrs.M.SINDHU

2. CONTENTS
ABSTRACT
INTRODUCTION
APPLICATIONS
SCOPE OF THE PROJECT
METHODOLOGY OF THE PROJECT
MATERIALS
LITERATURE REVIEW
TESTING OF MATERIALS
WORKABILITY TEST
MIX DESIGN
CASTING OF NOMINAL CONCRETE
CASTING OF HIGH DENSITY CONCRETE
COMPRESSIVE STRENGTH OF NOMINAL CONCRETE
COMPRESSIVE STRENGTH OF HIGH DENSITY CONCRETE
SPLIT TENSILE STRENGTH

3. ABSTRACT:
Concrete has an extensive role to play both in construction and
improvement of our civil engineering and infrastructure. It's great strength,
durability and versatility are properties that are utilized in the construction of roads,
bridges, airport, railways, tunnels, ports and harbours and many other major
infrastructure projects. To call the concrete, as high density concrete, it must have unit
weight ranging from 3360 kg/m³ to 3840 kg/m³. They can, however be produced with
the densities up to about 5280 kg/m³ High density concrete offers reliable, cost-efficient
radiation shielding and can be used alongside other shielding materials to maximize
protection in the available space. High density aggregates are the key ingredient in
High density concrete.
The more common aggregates used to achieve the required densities are Hematite,
Ilmenite, Magnetite and Steel aggregate. The concrete was studied using Hematite (iron
ore) having a density varies from 3400-3600 Kg/m³. Several properties of concretes with
design mix of M60 grade were also studied that include the compression, The high density
concrete was also compared with normal weight concrete of the same strength grade with
respect to the above parameters. Based on the experimental investigations carried on the
conventional concrete, high density Concrete has more Compressive strength, Split tensile
strength, flexural strength values are found out.

4. Introduction
Density greater than 2400 Kg/m3.
Generally greater than 2600 Kg/m3.
Require high density aggregates.
The specific gravity would be around 3.0-7.0.
PROPERTIES OF HIGH DENSITY CONCRETE:
Applications:
High density radiation shielding> Precast blocks> Mass concrete projects.
High density concrete applications columns.
Gravity seawall, coastal protection & breakwater structures Bridge counter
weights Ballast for ocean vessels> Off shore platforms noise and
vibration dampening.

5. SCOPE OF THE PROJECT
1. To give mix design for M60.
2. To determine density of concrete.
3. To determine compression strength, split tensile strength, flexural
strength for 7 & 28 days of curing.
4. To determine durability of high density concrete for 28 days.
GENERAL APPLICATIONS:
• Used in Nuclear power plants
• Offshore oil lines
• Construction of Industrial buildings
• Used as “Breakwater structures”.
• Used as Ballast

6. METHODOLOGYAND
EXPERIMENTAL PROGRAMME
The main objectives of this paper are as below:
1. To study the physical properties of High density concrete materials(sand,
coarse aggregate, hematite aggregate)
2. To find out Concrete mix design based on Indian Standard Recommended
Guidelines IS 10262:2009
3. To examine the workability of High density concrete incorporating hematite
aggregate.
4. To investigate the performance of these concrete terms of its compressive
strength, split tensile strength and flexural strength.
5. To compare the results of High density concrete incorporating hematite
aggregate

7. MATERIALS
MIX PROPORTION IS M60
1. CEMENT : OPC 53 GRADE
2. FINE AGGREGATE: SAND
3. COARSE AGGREGATE : GRAVEL & HAEMATITE ( 10% , 25% ,
50 % , 75 %)
4. SUPER PLASTIZER: FOSROC CONPLAST SP:430
Haematite:
Haematite is a mineral form of one of the oxides of iron. It is ferric oxide and is
designated as Fe2O3.
 It is the oldest known iron oxide mineral ever formed on earth.
 Haematite has a crystalline structure of rhombohedral lattice system.
The crystalline structure of haematite is same as that of ilmenite and corundum.
The colour of Haematite may vary from silver to grey, brown to reddish brown and
red. The streak of this will be rusty-red.

8. Aggregates for High Density Concrete:
HAEMATITE

9. Literature review
1. Athira Suresh, Ranjan Abraham (2015)
He studied on high density concrete using Haematite and Laterite as
replacement for coarse aggregates at percentages of 25%, 50% and 100%.
For M30 Grade concrete with W/C ratio as 0.42 Cubes, Cylinders and Beams
are casted.
Haematite concrete has achieved higher density than laterite concrete.
For 25% replacement, strength obtained was maximum than 50% and 100%
2.Harshavardhan C. and Bala Murugan S.
• In this study Barites are used to replace coarse aggregates which has a specific
gravity of 3.5-4.5.
• In this concrete is reinforced with steel fibres and exposed to elevated
temperatures.
• Barites have increased density of concrete by 1.44 times than the concrete with
normal aggregate.
• In this experiment Barites and Haematite stone aggregates are used for High
Density Concrete and Pumice and Vermiculite are used for achieving Low
Density concrete

10. 3. Mudasir Hussain Pandit et al (2014)
• He conducted an experiment on high density concrete using fly ash, micro silica and
recycled aggregate. Concrete is the most important engineering material and the
addition or replacement of some of the materials may change the properties of the
concrete.
• In recent years a lot of research work has been carried out in order to obtain more
durable and long term performance of concrete structures in the dynamic environment.
• In this experimental study, concrete mixes of different proportions with Fly ash, micro
silica and recycled concrete aggregate are prepared and tested
• after different days of moisture curing and what is the effect of these materials on the
strength of concrete is studied We are replacing the cement by Fly
• ash and Micro silica with 0%, 5%, 10% and 15% and the coarse aggregate with
Recycled Concrete Aggregate with 0%, 5%, 10% and 15%.

11. TESTING OF MATERIALS
1.CEMENT
 FINENESS OF CEMENT.
 SOUNDNESS OF CEMENT.
 SPECIFIC GRAVITY.
 NORMAL CONSISTENCY.
 INITIAL & FINAL SETTING TIME OF CEMENT.
2. FINE AGGREGATE
 FINENESS
 SPECIFIC GRAVITY
 BULK MODULUS
 WATER RATIO
3. Coarse aggregate
.
Fineness
Crushing strength
Impact
 WATER ABSORPTION TEST
SPECIFIC GRAVITY TEST
4. Haematite
5. Super plasticizer

12. 1.FINENESS OF CEMENT
 The fineness of cement is a measure of the size of the particles of cement and
is expressed in terms of the specific surface area of cement. This test is done
by following the IS: 4031 PART-1, 1996.
MATERIALS REQUIRED
 90 micron IS sieve,
 Weight balance has a capacity of 100g,
 Nylon or bristle brush
The fineness of Cement Formula:-
Weight of Cement (W1) = 100gms
Weight of Cement Retained on sieve(W2) = 8gms
%of Residue = Weight of sample on sieve/Total Weight of
Cement
= 8/100*100
= 8%

13. 2.SPECIFIC GRAVITY OF CEMENT
The specific gravity of the cement formula is as follows,
= (W2 – W1) / ((W2 – W1) – (W3 – W4) X 0.79)
Where,
W1 = Weight of Empty Flask
W2 = Weight of Flask + Cement.
W3 = Weight of Flask + Cement + Kerosene.
W4 = Weight of Flask + Kerosene.
Here, the specific gravity of kerosene is 0.79g/cc
Observation and calculation :
W1 = 30 gms
W2 = 44.7 gms
W3 = 85 gms
W4 = 72 gms
specific gravity of the cement =
( 44.7 -30 ) * 0.79
( 72 – 30 ) – ( 85 – 44.7 )
= 3.145
RESULT :
The Specific gravity of cement is = 3.145

14. 3.STANDRAD CONSISTANCY OF CEMENT
QUALITY OF
CEMENT
% OF WATER VOLUME OF
WATER(ml)
READING ON VICAT
APPARATUR (mm)
400gms 28 112 32
400gms 29 116 30
400gms 30 120 26
400gms 31 124 14
400gms 32 128 12
400gms 33 132 09
400gms 34 136 06
Standard consistency = Water required for penetration × 100
Weight of Cement
= 136 × 100 = 34 %
400

15. 4.INTIALAND FINAL SETTING TIME
TIME (sec) Reading on scale of vicat app(mm)
5 0
10 0
15 0
20 0
25 0
30 0
32 3
RESULT :  INTIAL SETTING TIME OF CEMENT = 30min
 FINAL SETTING TIME OF CEMENT = 10 hours

16. 1.SIEVE ANALYSIS OF FINE AGGREGATE
The aggregate passing 4.75mm sieve and retained on 0.075mm sieve are classified as fine
aggregate.
APPARATUS:
1.Fine aggregates
2.IS Sieve set from 4.75 mm to 75 micron.
3.Mechanical sieve shaker
4.Weighing balance
5.Scoop

17. IS
Sieve Size
Weight of
Fine
aggregate
Percent
Retained
Cumulative
Percent
Retained
Percent
passing
4.75 mm 0.0265 2.65 2.65 97.35
2.36 mm 0.0305 3.05 5.70 94.30
1.18 mm 0.121 12.1 17.80 82.20
600 micron 0.238 23.8 41.60 58.40
300 micron 0.367 36.7 78.35 21.65
150 micron 0.153 15.3 93.65 6.35
75 micron 0.0165 1.65 95.3 4.7
Pan 0.0001 0.00001 - -
Fineness
Modulus
3.35

18. IS SIEVE NO PERCENT OF PASSING GRADES
ZONE 1 ZONE 2 ZONE 3 ZONE 4
10 mm 100 100 100 100
4.75 mm 90-100 90-100 90-100 95-100
2.36 mm 60-95 75-90 85-100 95-100
1.18 mm 30-70 55-90 75-100 90-100
600 microns 15-34 35-59 60-79 80-100
300 microns 5-20 8-30 12-40 15-50
150 microns 0-10 0-10 0-10 0-15
GRADING TABLE
RESULT: In this case in comparison with table 4 IS:383-1970,it can be concluded that
The fine aggregate corresponds to Grading Zone II.

19. 2.Specific Gravity of fine aggregate
To determine the specific gravity and water absorption of fine aggregate
we require pycnometer, weighing balance, water, fine aggregate and
oven.
Observations and Calculations:
 Wa = 500 gms
 Wb= 1824 gms
 Wc= 1512 gms
 Wd= 497 gms
 Specific gravity = Wd / Wa-(Wb-Wc)
= 497 / 500-(1824-1512)
= 2.64

20. COARSE AGGREGATE
1.Specific Gravity:
To determine specific gravity of coarse aggregate we require an iron bucket and
oven. This test is done by following the IS 2386 part 3- 1963 code book.
Observations and Calculations:
 W1= 1995 gms
 W2= 2010 gms
 W3= 1238 gms
 Specific gravity = W1 / W2-W3
= 1995 / (2010-1238)
= 2.59

21. 2.WATER ABSORPTION
 To determine specific gravity of coarse aggregate we require an iron bucket and oven.
 This test is done by following the IS 2386 part 3- 1963 code book.
Observations and Calculations:
 W1= 1995 gms
 W2= 2010 gms
 Water absorption = W2-W1 / W1 = 2010-
1995/ 1995 = 0.70 %
Properties of Coarse Aggregate
S. NO PROPERTY RESULT
1 Specific gravity 2.59
2 Water absorption 0.70
3 Size of aggregate (mm) 20

22. MATERIAL USED IN EXPERIMENT
1.Ordinary Portland Cement
2.Natural Coarse Aggregates
3.Chemical admixture(conplastSP-430)
4.Concrete mixer
5.Trowel
6.Concrete specimens( cubes, beams, cylinder)
7.Water
8. Tampering rod
S.N0 PROPERTIES RESULTS
OBTAINED
1 SPECIFIC GRAVITY 4.2
2 WATER ABSORPTION(%) 2.0
3 SIZE OF AGGREGATE(mm) 20
PROPERTIES OF HAEMATITE:

23. S.NO MIXES
WATER
CEMENT
RATIO
SLUMP
VALUES
(mm)
SLUMP TYPE
01 NCC 0.29 10 mm True slump
02 HDC 10% 0.29 25 mm True slump
03 HDC 25% 0.29 20 mm True slump
04 HDC 50% 0.29 20 mm True slump
05 HDC 75% 0.29 10 mm True slump
WORKABILITY TEST :

24. Types of slump obtained :
Conventional slump HDC 10% slump HDC 25% slump

26. MIX DESIGN
Grade of concrete M60
(a) DESIGN
STIPULATION:- Target strength = 60Mpa
Max size of aggregate used = 20 mm
Specific gravity of cement = 3.15
Specific gravity of fine aggregate (F.A) = 2.6
Specific gravity of Coarse aggregate (C.A) = 2.64
Specific gravity of haematite =4.2
Dry Rodded Bulk Density of fine aggregate = 1726 Kg/m
Dry Rodded Bulk Density of coarse aggregate = 1638 Kg/m
STEP-1 :
Calculation for weight of Coarse Aggregate:
From ACI 211.4R Table 4.3.3 Fractional volume of oven dry Rodded
C.A for 20 mm size aggregate is 0.68m
Weight of C.A = 0.68*1638 = 1108.13 Kg/m

27. STEP-2 :
Calculation for Quantity of Water:
From ACI 211.4R Table 4.3.4 Assuming Slump as 50 to 75mm and for C.A size
20 mm the Mixing water = 148 ml
Void content of FA for this mixing water = 35%
Void content of FA (V)
V = {1-(Dry Rodded unit wt / specific gravity of FA*1000)}*100
= [1-(1726/2.6*1000)]*100
= 34.62%
Adjustment in mixing water = (V-35)* 4.55
= (34.62 – 35)*4.55
= -1.725 ml
Total water required = 148 + (-1.725) = 146.28 ml
STEP-3 :
Calculation for weight of cement
From ACI 211.4R Table 4.3.5(b)
Take W / C ratio = 0.29
Weight of cement = 146.28 / 0.29 = 504.21 kg/m

28. STEP- 4 :
Calculation for weight of Fine Aggregate:
Cement = 504.21 / 3.15*1000= 0.1616
Water = 146.28 / 1*1000= 0.1462
CA = 1108.13 / 3*1000= 0.3690
Entrapped Air = 2 / 100= 0.020
Total = 0.7376m3
Volume of Fine Aggregate= 1-0.7376
Weight of Fine Aggregate= 0.2624*2.6*1000= 683.24 kg/m
STEP-5 :
Super plasticizer:
For 0.8% = (0.8 / 100)*583.53 = 4.668 ml
STEP-6 :
Correction for water:
Weight of water (For 0.8%) =146.28 – 4.668 =141.61 kg/m3
Requirement of materials per Cubic meter
Cement = 504.21 Kg/m 3
Fine Aggregate = 683.24 Kg/m3
Coarse Aggregate = 1108.13 Kg/m3
Water = 141.61 Kg/ m3
Super plasticizers = 4.6681 / m3

29. So the final ratio becomes
Cement : Fine agg (kg/m3 ) : Coarse agg (kg/m3 ) : Water (l/m3 ):
Superplasticizer (l/m3 )
MIX PROPORTION : 1: 1.35 :2.19 :0.29 :0.8
DENSITY RESULTS
Conventional mix :
MIX TYPE CUBE
SAMPLES
EMPTY
WT OF
CUBES
CUBE+
CONCRET
E WT
DENSITY
(Kg/m3)
Avg density
(kg/m3)
Conventiona
l mix
1 7.02 15.02 2370.37
2381.23
(kg/m3)
2 7.14 15.32 2423.74
3 6.92 15.24 2349.62

30. High density concrete replacement of 10% hematite:
Mix type Cube
samples
Empty wt of
cube
Cube+concr
ete
Density
(kg/m3)
Avg density
(kg/m3)
HDC 10%
1 7.99 16.62 2844
2657.46
(kg/m3)
2 7.37 15.53 2521.48
3 7.63 15.82 2607.40
High density concrete replacement of 25% hematite:
Mix type Cube
samples
Empty wt
of cube
Cube+concr
ete
Density
(kg/m3)
Avg density
(kg/m3)
HDC 25%
1 8.21 16.71 2518.51
2704.19
(kg/m3)
2 7.97 16.57 2548.14
3 7.02 17.30 3045.92

31. High density concrete replacement of 50% hematite:
Mix type Cube
samples
Empty wt of
cube
Cube+concr
ete
Density
(kg/m3)
Avg density
(kg/m3)
HDC 50%
1 7.90 16.03 2408
2710.81
(kg/m3)
2 7.13 17.14 2965.92
3 8.01 17.32 2758.51
High density concrete replacement of 75% hematite
Mix type Cube
samples
Empty wt of
cube
Cube+concr
ete
Density
(kg/m3)
Avg density
(kg/m3)
HDC 75%
1 8.10 17.47 2761.48
2813.82
(kg/m3)
2 7.11 16.68 2877.03
3 7.06 16.52 2802.96

32. 2100
2200
2300
2400
2500
2600
2700
2800
2900
NCC HDC 10% HDC 25% HDC 50% HDC 75%
GRAPHICAL REPRESENTATION OF DENSITIES
ACHIEVED
Series 1 Column1 Column2

33. Compression strength results:
S.NO Mix Percent of
coarse Agg
used
Percent of
haematite
used
Compression
strength for
7days(N/mm2)
Compression
strength for
28days (N/mm2)
1 NCC 100% 0% 37.07 57.03
2 HDC 10% 90% 10% 25.77 59.92
3 HDC 25% 75% 25% 39.37 60.56
4 HDC 50% 50% 50% 41.08 63.2
5 HDC 75% 25% 75% 40.59 61.67

34. 37.07
28.07
39.37 41.08 40.56
57.03 54.92
60.56 63.2 61.67
0
20
40
60
80
NCC HDC 10% HDC 25% HDC 50% HDC75%
GRAPHICAL REPRESENTATION OF COMPRESSION
STRENGTH (N/MM2
7 days 28 days
SPLIT TENSILE STRENGTH RESULTS:
S.NO CONCRETE TYPE SPLIT TENSILE STRENGTH (MPA)
7 days 28 days
1 Conventional concrete 1.97 2.14
2 HDC 50% 2.47 3.3
3 HDC 75% 3.24 3.7

35. CONCLUSION
In this study, experimental studies on replacement of coarse aggregate with heavy
weight aggregates on the properties of concrete was investigated. For that purpose high
density aggregates are used in this study, Hematite Stone which having a density of
2300 kg/m3. Different test results were evaluated. Results show that density of concrete
increases with increase in the percentage of heavy weight aggregate. In this study
density up to 2900 kg/m3 is obtained for hematite concrete. Based on the results obtained
in this study, it may be seen that hematite could be used for making heavy weight
concrete, without affecting much the compressive strength, tensile strength of concrete.
Concretes with hematite have sufficient workability with respect to the conventional
concrete.

36. REFERENCES
 Harshavardhan.C, BalaMurugun, School of Civil and Chemical Engineering, VIT
University, Vellore: “Study on High Density Reinforced with steel fibre at elevated
temperatures”, ISSN 1898-6608, (ARPN) Vol.11, No-9, October 2016.
 Athira Suresh, Ranjan Abraham M.Tech student and Professor Ilahia College of
engineering and Technology, Kerala: “Experimental study on Heavy weight concrete
using Haematite and Laterite as Coarse aggregate”, (IJETT)-Volume 28 Number 4-
October2015.
 Indian Standard Codes IS 383:1970 IS 516 IS 10262:2009
 Kanwarjot Singh is the founder of Civil Engineering Portal, a leading civil
engineering website which has been awarded as the best online publication by CIDC.
He did his BE civil from Thapar University, Patiala and has been working on this
website with his team of Civil Engineers.
 B. Sagar Singh, K.V.Ramana ―Mechanical Properties Of Heavy Weight Concrete
Using Heavy Weight Coarse-Aggregate As Hematite (Fe58 High Grade Iron Ore).
International Journal of Research in Engineering and Technology.
 IS 12269-1989, ―Specification for Ordinary Portland cement 53 grade‖, Bureau of
Indian Standards, New Delhi.
 IS: 383-1970, ―Specification for Coarse and Fine Aggregate from natural sources
for Concrete‖, Bureau of Indian Standards, New Delhi
 IS.2386:1963, ―Methods of test for Aggregate of cconcret part 1, 2, 3 and 4, Bureau
of Indian Standards‖, New Delhi.